Organic binder for shaping ceramic, its production method and product employing the same

- Hitachi, Ltd.

A multilayer ceramic substrate comprising at least one ceramic layer made by laminating at least one ceramic green sheet layer and conductor layers formed on surfaces of the at least one ceramic green sheet layer into laminates and by sintering the resulting laminates. Each ceramic green sheet layer comprises a ceramic precursor composition comprising (I) 100 parts by weight of ceramic fine powder having an average particle diameter of 10 microns or less as component (C) and (II) 5 to 30 parts by weight, based on 100 parts by weight of the ceramic fine powder, of an organic binder for bonding the ceramic fine powder. The organic binder comprises (i) 100 parts by weight of a water insoluble polymer of at least one vinyl monomer as a major component of the organic binder, as component (A), and (ii) 1 to 9.5 parts by weight, based on 100 parts by weight of the component (A), of water soluble polymer as component (B). In the binder particles of the component (A) being dispersed by the component (B) in an aqueous medium resulting from suspension polymerization of the at least one vinyl monomer in water containing the water soluble polymer as a dispersion stabilizer.

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Claims

1. A multilayer ceramic substrate comprising at least one ceramic layer made by laminating at least one ceramic green sheet layer and conductor layers formed on surfaces of said at least one ceramic green sheet layer into laminates and by sintering the resulting laminates,

wherein each ceramic green sheet layer comprises a ceramic precursor composition comprising (I) 100 parts by weight of ceramic fine powder having an average particle diameter of 10 microns or less as component (C) and (II) 5 to 30 parts by weight, based on 100 parts by weight of the ceramic fine powder, of an organic binder for bonding the ceramic fine powder,
wherein said organic binder comprises:
(i) 100 parts by weight of a water insoluble polymer of at least one vinyl monomer as a major component of the organic binder, as component (A), and
(ii) 1 to 9.5 parts by weight, based on 100 parts by weight of said component (A), of water soluble polymer, as component (B);
particles of said component (A) being dispersed by said component (B) in an aqueous medium resulting from suspension polymerization of said at least one vinyl monomer in water containing said water soluble polymer as a dispersion stabilizer, wherein the water soluble polymer as component (B) comprises polyethylene oxide having an average viscometric molecular weight of 100,000 to 1,000,000.

2. A multilayer ceramic substrate comprising at least one ceramic layer made by laminating at least one ceramic green sheet layer and conductor layers formed on surfaces of said at least one ceramic green sheet layer into laminates and by sintering the resulting laminates,

wherein each ceramic green sheet layer comprises a ceramic precursor composition comprising (I) 100 parts by weight of ceramic fine powder having an average particle diameter of 10 microns or less as component (C) and (II) 5 to 30 parts by weight, based on 100 parts by weight of the ceramic fine powder, of an organic binder for bonding the ceramic fine powder,
wherein said organic binder comprises:
(i) 100 parts by weight of a water insoluble polymer of at least one vinyl monomer as a major component of the organic binder, as component (A), and
(ii) 1 to 9.5 parts by weight, based on 100 parts by weight of said component (A), of water soluble polymer, as component (B);
particles of said component (A) being dispersed by said component (B) in an aqueous medium resulting from suspension polymerization of said at least one vinyl monomer in water containing said water soluble polymer as a dispersion stabilizer, wherein the water soluble polymer as component (B) is poly(2-ethyloxazoline).

3. A multilayer ceramic substrate comprising at least one ceramic layer made by laminating at least one ceramic green sheet layer and conductor layers formed on surfaces of said at least one ceramic green sheet layer into laminates and by sintering the resulting laminates,

wherein each ceramic green sheet layer comprises a ceramic precursor composition comprising (I) 100 parts by weight of ceramic fine powder having an average particle diameter of 10 microns or less as component (C) and (II) 5 to 30 parts by weight, based on 100 parts by weight of the ceramic fine powder, of an organic binder for bonding the ceramic fine powder,
wherein said organic binder comprises:
(i) 100 parts by weight of a water insoluble polymer of at least one vinyl monomer as a major component of the organic binder, as component (A), and
(ii) 1 to 9.5 parts by weight, based on 100 parts by weight of said component (A), of water soluble polymer, as component (B);
particles of said component (A) being dispersed by said component (B) in an aqueous medium resulting from suspension polymerization of said at least one vinyl monomer in water containing said water soluble polymer as a dispersion stabilizer, wherein the component (A) comprises a polymer of n-butyl methacrylate and the water soluble polymer as component (B) comprises polyethylene oxide.

4. A multilayer ceramic substrate comprising at least one ceramic layer made by laminating at least one ceramic green sheet layer and conductor layers formed on surfaces of said at least one ceramic green sheet layer into laminates and by sintering the resulting laminates,

wherein each ceramic green sheet layer comprises a ceramic precursor composition comprising (I) 100 parts by weight of ceramic fine powder having an average particle diameter of 10 microns or less as component (C) and (II) 5 to 30 parts by weight, based on 100 parts by weight of the ceramic fine powder, of an organic binder for bonding the ceramic fine powder,
wherein said organic binder comprises:
(i) 100 parts by weight of a water insoluble polymer of at least one vinyl monomer as a major component of the organic binder, as component (A), and
(ii) 1 to 9.5 parts by weight, based on 100 parts by weight of said component (A), of water soluble polymer, as component (B);
particles of said component (A) being dispersed by said component (B) in an aqueous medium resulting from suspension polymerization of said at least one vinyl monomer in water containing said water soluble polymer as a dispersion stabilizer, wherein the water soluble polymer as component (B) comprises polyethylene oxide having a weight average molecular weight of 200,000 to 1,000,000.
Referenced Cited
U.S. Patent Documents
RE34887 March 28, 1995 Ushifusa et al.
4551357 November 5, 1985 Takeuchi
4613560 September 23, 1986 Dueber et al.
4795512 January 3, 1989 Nakatani et al.
4863683 September 5, 1989 Nakatani et al.
4868238 September 19, 1989 Craig
5034451 July 23, 1991 Tanaka et al.
5080958 January 14, 1992 Patterson et al.
5086093 February 4, 1992 Miller
5091033 February 25, 1992 Nakubayashi et al.
5230846 July 27, 1993 Tamhankar et al.
5274024 December 28, 1993 Koyama et al.
5314850 May 24, 1994 Miyahara
5328770 July 12, 1994 Yoshida et al.
5362791 November 8, 1994 Ebenhoech et al.
Foreign Patent Documents
0005598 January 1979 JPX
56-76405 November 1979 JPX
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60-180956 September 1985 JPX
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63-260855 October 1988 JPX
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Other references
  • Nilsen et al, "Dispersion of Laser--Synthesized Si.sub.3 N.sub.4 Powder in Non Aqueous Systems", Advances in Ceramics, Vol. 21: Ceramic Powder Science, 1987 pp. 537-547.
Patent History
Patent number: 5925444
Type: Grant
Filed: Feb 23, 1996
Date of Patent: Jul 20, 1999
Assignee: Hitachi, Ltd. (Tokyo)
Inventors: Nobuhito Katsumura (Yokohama), Fusaji Shoji (Yokohama), Madoka Kinoshita (Yokohama), Shousaku Ishihara (Chigasaki), Tsuyoshi Fujita (Yokohama)
Primary Examiner: Judy M. Reddick
Law Firm: Antonelli, Terry, Stout & Kraus, LLP
Application Number: 8/606,238